Apparatus for manufacturing floor mats



P 8, 1941- D. R. COTTERMAN 2,295,099

APPARATUS FOR MANUFACTURING FLOOR MATS Original Filed Oct. 16, 1939 2 Sheets-Sheet 1 INVENTOR. DON R. QOTTERMAN W fMif ATTORNE p 1942- o. R. COTTERMAN 2,295,099

APPARATUS FOR MANUFACTURING FLOOR MATS Original Filed Oct. 16, 1939 2 Sheets-Sheet 2 F'IG.6.

.INVENTOR. DON R. COTTERMAN I ATTORNEYS? of pile fabric. on the surfa Patented Sept. 8, 1942 APPARATUS FOR MANII IFACTURING FLOOR MA S,

Don R. Cotter-man, Pontiac,

Baldwin Rubber Company,

corporation of Michigan Original application 299,730. Divided 1940, Serial No. 332,343

13 Claims.

This invention relates to apparatus for manu facturing surface coverings, such as floor mats,

Mich., assignor to Pontiac, Mich., a

October 16, 1939, Serial No. and this application April 29,

and is a division of my copending application,

Serial No; 299,730, filed One of the principal resides in the provision expensive apparatus embodying means for making composite mats having a surface covering sheet of vulcanizable material and having a sheet ce covering sheet. Another object of this invention consists in the provision of apparatus having means for ouring the sheet of vulcanizable material to the desired contour while the sheet of pile fabric is in position thereon and also having means for protecting the pile of the fabric during the curing operation. A further feature of this invention resides in the provision of apparatus wherein both of the abovementioned sheets are formed to the shape October 16, 1939'. objects of this invention of the-contoured surface of a suitable form by subjecting the sheets. to the action of a fluid under pressure and wherein the pressure of the fluid is prevented from matting the pile onthe fabric by a sheet of carding material having rigid teeth or projections engageable with the sheet of fabric to space the pile on the latter from the adjacent surface ofthe form.

The foregoing, as well as other objects, will be made more apparent as this description proceeds, especially when considered in connection with the accompa ying drawings, wherein:

Figure 1 is a perspective view of a vehicle body flooring covered with a mat formed by the apparatus constructed in accordance with this invention;

Figure 2 is a sectional view taken substantially on the plane indicated by the line 22.of Figure l;v

Figure 3 is a plan view of .the molding form and illustrating a mat in association therewith;

Figure 4 is a sectional view taken substantially on the plane indicated by the line 4-4 of Figure 3;

Figure 5 is an enlarged sectional .view of a portion of the construction shown in Figure 4';

Figure 6 is a fragmentary diagrammatic view illustrating one type of pressure chamber that of a relatively simple, in-

a depressed portion I3 forming arecess l4 in trated ,as having a hump or." tunnel"intermediate the oppositesi'de edges for the purpose of accommodating parts (not shown) of the vehicle driving mechanism, and it will be observed from Figure 1 that the mat is tailored to neatly fit'the irregular floor surface.

In detail, the mat comprises a covering sheet I ll of vulcanizable material, such as rubber, and an insert l2 of a diiferent'material, such as pile fabric. The covering sheet II, is fashioned with -the top surface thereof. The depth of the recess l4 approximates the thickness of the pile of the fabric sheet l2 and the latter issecured within the recess.

Upon reference to Figure '2, it will be noted that the pile fabric has a base l5 secured to the upper surface of the recess and is further provided with pile I6 projecting above the base to -a position substantially flush' with the top surface of the covering ll surrounding the pile fabric. As will be more fully hereinafter set forth, the covering sheet II is cured against the surface of a form having a contour corresponding exactly to the surface contour of the floor to be covered by the sheet II and thepilefabric I2 is secured to the coverizig sheet during the .curing operation so that both sheets will neatlyfit the flooring surface.

It will also be observed from Figure 2 that a r fibrous backing I] may be secured to the covering sheet I I. This backing may be in the form of Jute, flock 'tion ll of the covering sheet and the portions surrounding this rece may be employed with the apparatus forming' the subject matter of this invention. a

The mat forming the subject matter-of this invention is especially designed for use as a cov- V ering for the irregular surface of a vehicle body floor, designated in Figures 1 and 2 by the reference character I0.- The flooring I0 is illusginal edge portions of the yond the adjacent edges of the sheet 20 and are return-bent to provide a continuous chamber 2| extending around the marginal edge of the sheet chamber overlapsthe top surface of the marginal edgeportionof 20.. The upper-wall 22 of the the sheet 20 and the interior of the chamber 2| communicates with the exhaust side of a suitable pump (not shown) through the medium'of- -a conduit 23.

As shown in Figure 4' a clearance 22' is provided betweencthe-flange 22 andthe or similar materials and. is applied in a manner to compensate for the difference in elevation between the base of the recessed por-J the plate. The marginal edge of the cover.

with a recess 24 in the recess 24 is a section of carding material 25 havportion 26 suitably anchored having rigid teeth or projections 21 projecting above the top surface of the sheet 20. Thebase 26 of the carding cloth possesses sufflcient flexibility to permit the same to conform to the contour of the adjacent surface of the form and, in the present illustration, follows the contour of the portion of the form which corresponds to the hump in the floor- The base 26 of the carding sheet 25 is preferably formed of a heat resisting material,.such as rubber or rubber substitutes,-and a plurality of staples or closely spaced pins are suitably anchored in the sheet while the latter is in its uncured state to form the teeth 21. The length of the portions of the staples or pins extending above the carding sheet is slightly greater than the depth of the pile IS on the fabric sheet l2 so that when the sheet I2 is positioned in an inverted position on the carding cloth (Figure'b),

ing a flexible base in the recess and the pile I6 is, in efiect, suspended in a manner to prevent matting of the pile against the form 18.

As will 'be more fully hereinafter set forth, form Isis adapted to be supported in a chamber 28 shown diagrammatically in Figure 6 as comprising a base 30 and a cover 3| removably supported on the base 30. A suitable sealing strip 32 is secured to the base 30 and is channel shaped in cross section for receiving the mar- The base is apertured to receive the suctionconduit 23 and the cover is apertured to receive a fluid pressure supply conduit 29. The above construction is merely shown for the purpose of illustration and forms no part of this invention.

Operation In actual practice, a pile. fabric sheet of the proper size is placed on the teeth of the carding material in an inverted position so that the teeth of the carding material contacts the top surface of the base l5 of the pile fabric sheet. When positioned in'this manner, the pile It on the fabric sheet, in effect, extends between the rigid teeth 21 of the carding material in the manner designated by the enlarged sectional view shown in Figure 5.

After the pile fabric sheet is properly positioned on the carding material, a sheet of vulcanizable .material, such as uncured rubber, is placed over the mold form I! with the marginal edge portions overlapping the continuous flange 22 and with the intermediate portion extending over 'the underside of.the base l5- on the pile fabric in contact with the base. The mold form It is' then located within the pressure chamber 28 and preheated fluid under pressure such as steam is introduced into the chamber through the conduit 29. The fluid under pressure is appliedto the exposed surface of the uncured sheet in the manner designated by.the arrows in F18- ure 4 and the pressure is sumcient to conform both the uncured covering sheet andthe sheet of pile fabric to the contour of the top surface of the mold form It. Als0,'the fluid under pressure is preheated to vulcanize or cure the rubber sheet to the contour of the form which, as stated above, corresponds to the contour of the flooring. It may be pointed out at this time that the teeth 21 of the carding material sufflcient rigidity to withstand the pressure of the vulcanizing fluid medium applied to the uncured sheet and, accordingly, the pile ii of the fabric sheet I2 is prevented from matting during the application of the vulcanizing pressure.

It has previously been stated that the carding sheet has a base portion 26 formed of uncured rubber or rubber-like material and that the pins or staples are secured in the base while the latter is in its uncured state. If desired, the carding sheet is positioned on the form while the base portion 25 is in its uncured state and is cured to the contour of the form during repeated use in forming the contoured mats.

In order to maintain the vulcanizable material in proper position on the contoured form prior to introducing the form into the pressure chamber 28 and at the same time exhaust any air that may be trapped between the adjacent surfaces of the form and vulcanizable material, the marginal chamber 2| is exhausted. As stated above, the marginal portions of the vulcanizable material extend over the flange 22 and the resulting suction effected through the chamber 2| provides an effective seal around the material. Accordingly, the material will accurately conform to the contoured surface of the mat under the pressure of the fluid medium in the chamber 28. It will, of course, be understood that any tendency for the suction action to draw the pile fabric sheet toward the contoured surface of the form is prevented by the rigid teeth 21 on the carding sheet 25.

During the interval the uncured sheet is'vulcanized to the contour of the,mold form II, the base I! of the pile fabric is permanently united to the adjacent surface of the uncured sheet.

This may be accomplished by vulcanizing the the base prior to placing the uncured sheet of stock over the mold form ll. On the other hand, a bituminous binder may be employed, instead of cement, and, in such a case, a binder is selected which will become tacky during the vulcanizing temperatures. In any event, the pile fabric is secured in place on the sheet of vulcanizable material during the time the latter is cured to the contour of the mold form and this, of course, is desirable in that it not only reduces the cost of manufacture, but also appreciably expedites the time required to make the mat.

When the vulcanizing process previously referred to is completed, the mold form It is removed from the pressure chamber 28 and a mat is produced which corresponds exactly to the contour of the flooring to be covered thereby and which is provided with an insert of fabric pile. The backing material I1 is then cemented or otherwise suitably secured to the undersurface of the mat and the latter is ready for installation. What I claim as my invention is:

1. In apparatus for-manufacturing floor coverings, a form having a surface adapted to supjections extending toward the sheet of vulcanizable stock, said projections adapted tosupport -a sheet of pile fabric with the base of the fabric engaging the sheet of vulcanizable stock and with the pile extending toward the form between the projections, and means for curing the sheet of vulcanizable stock while in engagement withthe base of the pile fabric sheet.

2. In apparatus for manufacturing floor coverings, a form having a contoured surface adapted to support a sheet of vulcanizable stock, a sheet of material positioned on the contoured surface and possessing suflicient flexibility to conform to the contour of saidsurface, a plurality of closely spaced rigid pins projecting from the second sheet of material toward the vulcanizable stock and adapted to support a sheet of pile composite mats, a form having a contoured surface adapted to support a sheet of vulcanizable stock, a strip of carding material positioned on the contoured surface of the form and possessing sufficient flexibility to conform to the latter surface, rigid teeth extending upwardly from ,the

carding material adapted to support a sheet of' pile fabric with the pile extending downwardly toward the form between the teeth and with the base contacting the adjacent surface of the vulcanizable stock, and means for' urging the fabric with the pile extending toward the second named sheet between the pins and with the base portions thereof engageable with the adjacent surface of the vulcanizable stock, and means for applying fluid under pressure on the surface of 7 adapted to support a sheet of vulcanizable stock,

a sheet of material positioned on the contoured surface of the form over said recess and conforming in contour to said surface of the form, a

plurality of closely spaced rigid pins projecting from said sheet of material toward the vulcaniz: able stock and adapted to support a sheet of pile fabric with the pile extending toward said sheet of material between, the pins on the latter and with the base portion thereof engageable with the adjacent surface of the vulcanizable stock, and means for applying fluid under pressure on the surface of the vulcanizable stock opposite the surface adjacent the base of the pile fabric to urge both the vulcanizable stock and sheet of pile fabric in a direction toward the contoured surface of the form, the rigidity of the pins being suflicient to prevent matting of the pile under the action of the pressure.

4. In apparatus for manufacturing contoured mats, a form having a contoured surface adapt-' ed to support a sheet of stock, a strip of card ing material secured to the contoured surface of the form and havingrigid teeth adapted to support a sheet of pile fabric with the pile of the fabric extending toward the form between the teeth and with the base of the fabric contacting the surface of the sheet of stock facing the form,' and means for urging thestock and sheet of pile fabric toward the form.

5. In apparatus for manufacturing contoured vulcanizable stock in intimate contacting relationship with-the form and with the base of the pile fabric, the teeth on the carding material being sufflciently rigid to counteract the action of the last named means and prevent matting of the pile fabric.

i 7. In'apparatus for manufacturing contoured composite mats, a form having a contoured surface adapted to support a sheet of vulcanizable stock, a strip of carding material secured to the contoured surface of the form and having rigid teeth extending upwardly to support a sheet of pile fabric with the pile extendingdownwardly toward the form and' with the .base portion thereoiv contacting the adjacent surfac of the vulcanizable stock, and means for applying a preheated fluid under pressure'against the exposed surfaceof the vulcanizable stock to cure the latter to the contour of the form, the'rigidity of the teeth on the carding material being suflicient to hold the pile fabric in-spaced relation to the form against the action of said fluid pressure.

8. In, apparatus for manufacturing floor coverings having a sheet of vulcanizable material and having a strip of pile fabric on said sheet with the pile extending upwardly from the top of the sheet, a form'having a surface adapted to support a sheet of vulcanizable stock with a strip of pile fabric located between the stock'and form in such a manner that the pile on the fabric sheet extends towardthe form, and a sheet of carding material on the form opposite the sheet of pile fabric and having closely spaced rigid teeth extending between the pile of the fabric into engagement with the base portion of the fabric to prevent matting of the pile against the form;

9.. In, apparatus for manufacturing floor cov- I erings having .a sheet of vulcanizable material -anrihaving a strip of pile fabric on said sheet with the pile extending upwardly from the top of the sheet, a form having a surface adapted to mats, a form having a contoured surface adapted I to support a sheet of stock, astrip of carding material secured to the contoured surface of the form and having rigid teeth adapted to support a sheet of pile fabric with the'pile of the fabric extending toward the form between the teeth and with the base of the fabric contacting the adjacent surface of the, stock,-an d a vacuum chamber communicating. with the joint between the stock and adjacent surface of the form to urge the stock and pile fabric in a direction toward the form;

6. In apparatus for manufacturing contoured support-a sheet of vulcanizable stock with a strip of pile fabric positioned between the stock. and the form'in such .a manner that thepile on the fabric extends toward the form, means for applying fluid-under pressure on the surface of the stock opposite the surface adjacent the base of the pile fabric to urge the stock and pile fabric toward the form, and a sheet of carding ma terial mounted on the form opposite the strip of pile fabric and having rigid teeth projecting between the pile of the fabric into engagement with the base portion of the fabric to prevent matting of the pile against the-form by the action or. the fluid pressure.

10. In apparatus for manufactiu'ing floor coverings having a sheet of vulcanizable material and having a strip of pile fabric on said sheet with the pile extending upwardly from the top of the sheet, a mold form having a contoured surface and having closely spaced teeth projecting from the contoured surface with the free ends of the teeth lying in a plane parallel to the plane of the contoured surface of the form, said contoured surface adapted to support a sheet of vulcanizable stock with a strip of pile fabric located between the stock and contoured surface of the form in such a manner that the pile on the fabric strip extends toward the form between the teeth proiecting from the contoured surface of said form, and means for curing the vulcanizable stock to the contour of the form.

11. In apparatus for manufacturing floor .coverings having a sheet of vulcanizable material and having a strip of pile fabric on said sheet with the pile extending upwardly from the top of the sheet, a form over which a sheet of vulca'nizable material and a sheet of pile fabric are adapted to be placed with the pile fabric sheet interposed between the form and sheet of vulcanizable material and with the pile extending in a direction toward the form, means for applying heat under pressure against the top surface of the sheet of vulcanizable material to cure the latter, said means also operable to urge the sheet of vulcanizable material mm intimate 0011M with the base of the pile fabric sheet and to urge both the sheets toward the form, and means operating independently of the pile for holding the form. said form also adapted to support a sheet of vulcanlzable stock "with avportion of the stock extending over the base of the pile fabric sheet, means for applying heat under pressure on the top surface of the sheet of vulcanizable stock tocure the latter, said means also operable to urge the vulcanizable sheet into intimate contact with the base of the pile fabric sheet and to also urge both sheets in a direction toward the form, and means operating independently of the pile for holding the base of the pile fabric sheet spaced above the form during the curing operation to prevent matting of the pile against the form by the heat under pressure.

13. In apparatus for manufacturing composite mats, a form over which a sheet of vulcanizable material and a sheet of pile fabric are adapted to be placed with the pile fabric sheet interposed between the form and sheet of vulcaniza-ble material and with the pile extending in a direction toward the form, means for applying heat under pressure against the top surface of the sheet of form during the curing operation to prevent matting of the pile against the form by the heat under pressure.

DON R. CO'I'I'ERMAN. 

